Door with interior protective coating

Abstract

An exemplary door has a hollow interior, and includes a first panel and a second panel that are secured to one another such that a gap is formed therebetween. Each panel has an interior side that faces the hollow interior and an exterior side that is exposed to view. The door further includes a protective coating system that is disposed on the interior side of at least one of the panels. The coating is formed of a two-part elastomeric composition, such as a two-part elastomeric polyurethane composition or a two-part elastomeric polyurea composition. The coating improves the thermal, acoustic, and/or ballistic performance characteristics of the door.

What is claimed is: 
     
       1. A door, comprising:
 a protective coating system comprising an elastomeric material, the protective coating system comprising a first protective coating and a second protective coating; 
 a first metal panel having a first exterior side and a first interior side opposite the first exterior side, wherein the elastomeric material is applied to the first interior side and forms the first protective coating thereon, and wherein the elastomeric material is not applied to the first exterior side; and 
 a second metal panel arranged substantially parallel to the first metal panel, the second metal panel having a second exterior side and a second interior side opposite the second exterior side, wherein the elastomeric material is applied to the second interior side and forms the second protective coating thereon, and wherein the elastomeric material is not applied to the second exterior side; 
 wherein the second panel is coupled to the first panel such that the first interior side faces the second interior side; and 
 wherein the first protective coating faces the second protective coating and a gap is formed therebetween. 
 
     
     
       2. The door of  claim 1 , wherein the elastomeric material is formed of a two-part elastomeric composition. 
     
     
       3. The door of  claim 1 , wherein the elastomeric material is one of an elastomeric polyurethane material or an elastomeric polyurea material. 
     
     
       4. The door of  claim 1 , wherein the gap is free of infill material. 
     
     
       5. The door of  claim 1 , wherein the protective coating system is contained entirely within the door. 
     
     
       6. The door of  claim 1 , wherein the first protective coating covers the entire first interior side, and wherein the second protective coating covers the entire second interior side. 
     
     
       7. The door of  claim 1 , wherein the protective coating system is structured to reduce transmission of sound through the door, to reduce transmission of heat through the door, and to increase a structural strength of the door. 
     
     
       8. A door, comprising:
 a first panel having a first exterior side and a first interior side opposite the first exterior side; 
 a second panel having a second exterior side and a second interior side opposite the second exterior side, wherein the second panel is coupled to the first panel, wherein the first exterior side and the second exterior side are exposed, wherein the first interior side faces the second interior side such that the first interior side and the second interior side are concealed within the door, and wherein a gap is formed between the first interior side and the second interior side such that the door has a hollow interior; and 
 a protective coating system disposed on at least one of the first interior side and the second interior side, wherein the protective coating system comprises at least one protective coating formed of a cured two-part elastomeric composition, wherein the cured two-part elastomeric composition is disposed on neither the first exterior side nor the second exterior side, and wherein the protective coating system is positioned in the hollow interior of the door such that the protective coating system is concealed within the door. 
 
     
     
       9. The door of  claim 8 , wherein the hollow interior of the door is free of infill material. 
     
     
       10. The door of  claim 8 , wherein the lining includes a first lining portion disposed on the first interior side and a second lining portion disposed on the second interior side, and wherein the gap is formed between the first lining portion and the second lining portion. 
     
     
       11. The door of  claim 8 , wherein the lining coats substantially all of the first interior side and substantially all of the second interior side. 
     
     
       12. The door of  claim 8 , wherein the lining is disposed entirely within the hollow interior of the door such that no portion of the lining is exposed to view. 
     
     
       13. The door of  claim 8 , wherein each of the first panel and the second panel is formed of a metal. 
     
     
       14. The door of  claim 8 , wherein each of the first panel and the second panel is formed of a metal. 
     
     
       15. The door of  claim 14 , wherein the first panel and the second panel are arranged in parallel to one another. 
     
     
       16. A door, comprising:
 a first door panel and a second door panel arranged substantially parallel to one another, wherein each of the first door panel and the second door panel has an interior side surface and an opposite exterior side surface; and 
 a two-part elastomeric composition having a first part and a second part that are intermixed with one another to provide a mixed elastomeric composition; 
 wherein the mixed elastomeric composition is applied to the interior side surface of the first door panel and to the interior side surface of the second door panel; 
 wherein the mixed elastomeric composition is cured to form a cured elastomeric composition defining a first protective coating on the interior side surface of the first door panel, and a second protective coating on the interior side surface of the second door panel; 
 wherein the first door panel is secured to the second door panel such that the interior side surface of the first door panel and the interior side surface of the second door panel face one another; and 
 wherein the first protective coating faces the second protective coating and a gap is defined therebetween. 
 
     
     
       17. The door of  claim 16 , wherein the elastomeric composition has an apply thickness when the elastomeric composition is applied to the interior side surface of the first door panel;
 wherein the first protective coating has a cure thickness when the first protective coating is fully cured; and 
 wherein the apply thickness is the same as the cure thickness. 
 
     
     
       18. The door of  claim 17 , wherein the first protective coating is a substantially non-expandable coating. 
     
     
       19. The door of  claim 17 , wherein the elastomeric composition has a second apply thickness when the elastomeric composition is applied to the interior side surface of the second door panel;
 wherein the second protective coating has a second cure thickness when the second protective coating is fully cured; and 
 wherein the second apply thickness is substantially the same as the second cure thickness. 
 
     
     
       20. The door of  claim 16 , wherein a surface of the first side surface of the at least one of the first door panel and the second door panel is roughened prior to application of the mixed elastomeric composition thereto. 
     
     
       21. The door of  claim 16 , wherein the two-part elastomeric composition is one of a two-part elastomeric polyurethane composition and a two-part elastomeric polyurea composition. 
     
     
       22. The door of  claim 16 , wherein each of the first door panel and the second door panel is formed of a metal.